Molded abrasive brush

ABSTRACT

A molded abrasive brush having a backing with a plurality of bristles extending therefrom. The backing and bristles are preferably integrally molded. The brush is molded from a moldable polymer such a thermoset polymer, thermoplastic polymer, or thermoplastic elastomer. The moldable polymer includes a plurality of organic or inorganic abrasive particles interspersed throughout at least the bristles, and can be interspersed throughout the brush. The moldable brush can include an attaching means molded integrally with the backing. Also disclosed is a method of making a molded abrasive brush and a method of refining a workpiece surface with a molded abrasive brush.

TECHNICAL FIELD

The present invention relates generally to an abrasive brush having aplurality of bristles unitary with the backing, and more particularly toan abrasive brush made by injection molding a mixture of a moldablepolymer and abrasive particles.

BACKGROUND OF THE INVENTION

Brushes have been used for many years to polish, clean and abrade a widevariety of substrates. These brush products typically have a pluralityof bristles that contact the substrate. Abrasive particles can be addedto bristles to increase their abrasiveness. There are many manufacturingsteps necessary to manufacture a conventional abrasive brush havingbristles which contain abrasive particles. A mixture of abrasiveparticles and a thermoplastic binder may be combined and then extrudedto form a bristle. The bristle is then cut to the desired length. Aplurality of these bristles are then mechanically combined to form abrush segment. Next, a plurality of these brush segments may beinstalled on a hub or plate to form a brush.

One example of such a brush is disclosed in U.S. Pat. No. 5,045,091,"Method of Making Rotary Brush With Removable Brush Elements,"(Abrahamson et al.). In Abrahamson et al., a plurality of abrasivebristles are mechanically clamped together and a root system isinstalled to form a brush segment. A plurality of these brush segmentsare installed on a rotary hub. Another arrangement for mechanicallymounting bristles on a hub to form a brush segment is disclosed in U.S.Pat. No. 5,233,719, "Apparatus and Brush Segment Arrangement forFinishing Wheel Brushes," (Young et al.). Young et al. teach a brushsegment comprising a substrate with a carpet of bristles mounted on oneside of the substrate, by means of a polymeric resin for example, and aroot system extending from the opposite side of the substrate forengagement with a rotary hub. U.S. Pat. No. 5,400,458 (Rambosek) teachesa brush segment having a plurality of bristles embedded in a polymericbase portion. A root means for attaching the segment to a hub can beintegrally molded with the base.

U.S. Pat. No. 5,233,794, "Rotary Tool Made of Inorganic Fiber-ReinforcedPlastic," (Kikutani et al.), discloses a rotary tool 5 having a rotatingtip formed integrally with a shaft 3. The rotary tool is formed of athermosetting resin containing inorganic long fibers with a high degreeof hardness as an abrasive means in an amount from 50% to 81% by volume.The long inorganic fibers can have a diameter in the range of 3 μm to 30μm. In one of the embodiments of Kikutani et al., the rotating tip isformed as a column or cylinder with elements 6 which correspond to thebristle of a brush extending from the tip, as is reproduced in FIG. 10.

U.S. Pat. Nos. 5,152,917 and 5,304,223 (Pieper et al.) teach coatedabrasive articles comprising precisely shaped abrasive composites bondedto a backing. The abrasive composites comprise binder and abrasiveparticles. The precisely shaped composites can be in the form of, forexample, pyramids, sawtooth grooves, or linear grooves. The maximumdistance between corresponding points on adjacent composite shapes canbe less than one millimeter. The coated abrasive of Pieper et al. can bemade, for example, according to the following general procedure. First,a slurry containing abrasive grains and binder is introduced to aproduction tool. Second, a backing is introduced to the outer surface ofthe production tool such that the slurry wets the front side of thebacking. Third, the binder is at least partially cured. Fourth, theproduction tool is removed from the backing.

U.S. Pat. No. 5,316,812 (Stout et al.) teaches a thermoplastic backingfor use in abrasive articles. A resinous binder adheres abrasiveparticles to the thermoplastic backing.

U.S. Pat. Nos. 5,174,795 and 5,232,470 (Wiand) teach a planar abrasivearticle comprising a sheet portion with a plurality of protrusionsextending therefrom. Abrasive particles are homogeneously dispersedthroughout the moldable material comprising the article. Wiand teachesone embodiment having short protrusions extending 1.6 mm (0.063 in) fromthe backing and having a 3.2 mm (0.125 in) diameter, and anotherembodiment having short protrusions extending 1.3-1.5 mm (0.05-0.06 in)from the backing and having a 1.3 mm (0.05 in) diameter.

G.B. Patent Application No. 2.043,501, (Dawkins) discloses an abrasivearticle for polishing ophthalmic workpieces. The abrasive article ismade by injection molding a mixture of abrasive grains and athermoplastic binder to form an abrasive article comprising a flexiblebacking having a plurality of upstanding projections, the ends of whichact as operative abrading surfaces.

Co-pending U.S. patent application Ser. No. 08/351,884 (Pihl), issued asU.S. Pat. No. 5,443,906, discloses an extruded abrasive filamentincluding a first elongate filament component having a continuoussurface throughout its length and including a first hardened organicpolymeric and a second elongate filament component coterminous with thefirst elongate filament component, including a second hardened organicpolymeric material in melt fusion adherent contact with the firstelongate filament component along the continuous surface. The secondhardened organic polymeric material can be the same or different thanthe first hardened organic polymeric material. At least one of the firstand second hardened organic polymeric materials includes a thermoplasticelastomer having abrasive particles adhered therein. Also disclosed isan abrasive article comprised of at least one abrasive filament mountedto a substrate such as a hub adapted to be rotated at a high rate ofrevolution.

Co-pending U.S. patent application Ser. No 08/066,862 (Barber), issuedas U.S. Pat. No. 5,460,883, discloses a composite abrasive filamentwhich includes at least one preformed core at least partially coatedwith a thermoplastic elastomer having abrasive particles dispersed andadhered therein, the thermoplastic elastomer and abrasive particlestogether comprising a hardened composition. The composite abrasivefilament has a hardened composition over at least a portion, preferablyover the entire surface of at least one preformed core. The preformedcore is formed in a step separate from and prior to one or more coatingsteps, one of which coats the preformed core with abrasive-filledthermoplastic elastomer.

It is seen that there is a need to provide an abrasive brush that iseasily and inexpensively manufactured, and which provides suitabledurability and abrading characteristics.

SUMMARY OF THE INVENTION

One aspect of the present invention presents an integrally moldedabrasive brush comprising a generally planar flexible base having afirst side and a second side, and a plurality of bristles extending fromthe first side of the base. The bristles have an aspect ratio of atleast 2 and are integrally molded with the base. The molded abrasivebrush comprises a moldable polymeric material which includes abrasiveparticles interspersed throughout at least the bristles. In anotherembodiment, the bristles have an aspect ratio of at least 5 and in yetanother embodiment, the bristles have an aspect ratio of at least 7.

In another aspect of the present invention, the molded abrasive brush ismade of a thermoplastic elastomer. The thermoplastic elastomer cancomprise a polyester based thermoplastic elastomer. The thermoplasticelastomer can include a lubricant mixed therewith. In one embodiment,the molded abrasive brush comprises a thermoplastic elastomer withabrasive particles interspersed throughout the abrasive brush. Theabrasive particles can comprise inorganic abrasive particles or organicabrasive particles.

In yet another aspect of the present invention, the bristles of themolded abrasive brush are tapered so as to be wider at the root adjacentthe base than at the tip. In one version, the bristles are taperedthroughout their length, in another version the bristles are tapered ata first portion adjacent the root and have a constant thickness at asecond portion adjacent the tip.

In a further aspect of the present invention, the molded abrasive brushincludes an attachment means provided on said base for attaching saidabrasive brush to a tool. The attachment means can comprise a threadedstud integrally molded with the base extending from the second side ofthe base.

In yet a further aspect of the present invention, the base of the moldedabrasive brush includes a reinforcing means. In one version, thereinforcing means comprises a reinforcing substrate provided on thesecond side of the base.

In another aspect of the present invention, an integrally moldedabrasive brush is presented, comprising a base having a first side and asecond side, and a plurality of bristles extending the first side ofsaid base and integrally molded with the base. The molded abrasive brushcomprises a thermoplastic elastomer including abrasive particlesinterspersed throughout at least the plurality of bristles. In anotheraspect, the thermoplastic elastomer is selected from: polyester-basedthermoplastic elastomer, nylon-based thermoplastic elastomer, andpolyurethane-based thermoplastic elastomer.

In a further aspect of the present invention, an integrally moldedabrasive brush is presented, comprising a base having a first side and asecond side, a plurality of flexible bristles extending from the firstside of the base integrally molded with the base, and a threaded studintegrally molded with the base and extending from the second side ofthe base for attaching said abrasive brush to a tool to rotate theabrasive brush. The molded abrasive brush comprises a moldable polymericmaterial which includes abrasive particles interspersed throughout atleast the plurality of bristles.

In yet a further aspect of the present invention, an integrally moldedabrasive brush is presented comprising a base having a first side and asecond side, and a plurality of bristles extending from the first sideof said base integrally molded with said base. The molded abrasive brushcomprises a moldable polymeric material which includes organic abrasiveparticles interspersed throughout at least the bristles. In anotheraspect, the polymeric material comprises organic abrasive particlesinterspersed throughout the abrasive brush.

The present invention also includes a method of making a molded abrasivebrush. The method comprises the steps of: a) mixing a moldable polymerand abrasive particles together to form a mixture; b) heating themixture to form a flowable material; and c) injecting the flowablematerial under pressure into a mold to form an abrasive brush, whereinthe brush comprises: a generally planar flexible base having a firstside and a second side, and a plurality of bristles extending from thefirst side of the base, wherein the bristles have an aspect ratio of atleast 2 and are integrally molded with the base. In another aspect ofthe inventive method, step a) comprises mixing a thermoplastic elastomerwith abrasive particles. In a further aspect of the inventive method,step a) further comprises mixing a lubricant with the mixture.

Also presented is a method of refining a workpiece surface, comprising:a) providing an integrally molded abrasive brush comprising: a basehaving a first side and a second side, and a plurality of bristlesextending from the first side of the base, wherein the bristles areintegrally molded with the base; and wherein the molded abrasive brushcomprises a thermoplastic elastomer including abrasive particlesinterspersed throughout at least the plurality of bristles; b)contacting the bristles against the workpiece surface; and c) moving theabrasive brush relative to the workpiece to thereby refine the workpiecesurface. In another aspect of the inventive method, step c) comprisesremoving workpiece material from the workpiece surface, and the abrasiveparticles comprise inorganic abrasive particles. In a further aspect ofthe inventive method, the workpiece surface includes a foreign materialthereon, the abrasive particles comprise organic abrasive particles, andstep c) comprises removing foreign material from the workpiece surface.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be further explained with reference to theappended Figures, wherein like structure is referred to by like numeralsthroughout the several views, and wherein:

FIG. 1 is a cross-sectional view of a first embodiment of an abrasivebrush made in accordance with the present invention;

FIG. 2 is a plan view of the abrasive brush of FIG. 1;

FIG. 3 is an elevational view of the abrasive brush of FIG. 1 inoperation;

FIG. 4 is a cross sectional view of one embodiment of the bristleportion of the present invention;

FIG. 5 is a cross sectional view of a further embodiment of the bristleportion of the present insertion;

FIG. 6 is a partial cross sectional view of an alternate embodiment ofan abrasive brush including a reinforcing means according to the presentinvention;

FIG. 7 is a view like FIG. 6 of an alternate reinforcing means accordingto the present invention;

FIG. 8 is a schematic illustration of an apparatus and method forcarrying out the present invention;

FIG. 9 is a partial cross sectional view of a mold and ejector accordingto the present invention;

FIG. 10 is an isometric view of a known rotary tool;

FIG. 11 is a plan view of an alternate embodiment of an abrasive brushmade in accordance with the present invention;

FIG. 12 is a cross-sectional view of the brush of FIG. 11 taken alongplane 12--12;

FIG. 13 is a plan view of a brush assembly according to the presentinvention having a plurality of abrasive brushes mounted on a backing;and

FIGS. 14A-14D are cross-sectional views taken along plane 14--14 of thebrush assembly of FIG. 13, showing alternate embodiments of means formounting the abrasive brushes on the backing.

DETAILED DESCRIPTION OF THE INVENTION

This invention pertains to a molded abrasive brush, a method of making amolded abrasive brush and a method of using a molded abrasive brush.

Referring to FIGS. 1 and 2, abrasive brush 10 comprises a planar base 12having first side 14 and second side 16. A plurality of bristles 18project outwardly from first side 14 of base 12. In between bristles 18there are spaces in which the first side 14 of the base 12 is exposed.Abrasive brush 10 is preferably integrally molded and comprises agenerally homogenous composition of abrasive particles 26 in a moldablepolymer 28.

The materials, manufacturing process and abrasive brush configurationwill depend upon the desired refining application. As used herein, theterm "refine" includes at least one of the following: remove a portionof a workpiece surface; impart a surface finish to a workpiece; clean aworkpiece surface, including removing paint or other coatings, gasketmaterial, corrosion, or other foreign material; or some combination ofthe foregoing. In some applications, it may be preferred to provideaggressive abrasive characteristics, in which case the abrasive brushmay comprise larger size abrasive particles, harder abrasive particles,a higher abrasive particle to binder ratio, or some combination of theabove. In other applications, it may be preferred to provide a polishtype finish to the surface being refined, or to clean a surface withoutremoving surface material itself, in which case the abrasive brush mayemploy smaller abrasive particles, softer abrasive particles, lowerparticle to binder ratio, or some combination of the above. It ispossible to employ abrasive particles 26 of varied composition andhardness to obtain the desired abrading characteristics.

Base

In a preferred embodiment, the base 12 is generally planar. However, itis within the scope of the invention to have a contoured or curved base.For example, base 12 may be convex, concave, or conical in shape. Insuch an arrangement, the bristles 18 may be of uniform length in whichcase tips 22 of the bristles will not be coplanar, or bristles may be ofvarying length in which case the tips may be coplanar. The base 12 mayoptionally contain a lip around its periphery where a portion of thebase extends radially beyond the outermost bristles 18. The size of thelip is preferably minimized so that it does not interfere withmaneuvering the abrasive brush 10 against surfaces bounding and at anangle relative to the surface of the workpiece.

In one preferred embodiment, the base 12 is of a suitable material andthickness to provide a flexible base 12, which helps maintain morebristles in contact with an uneven or irregular workpiece. The base 12preferably is capable of flexing at least 10°, more preferably at least20°, and still more preferably at least 45° without damage orsubstantial permanent deformation to the base. The desired degree offlexing also depends upon the intended refining application and thematerial of the workpiece. The ability to refine an uneven or irregularworkpiece is enhanced when the flexible base 12 is combined withflexible bristles 18. The base 12 can preferably have a thickness offrom about 1.0 to 15.0 mm, more preferably from about 1.5 to 10 mm,still more preferably from about 2.0 to 6 mm, and most preferably fromabout 2.5 to 4.0 mm. Base 12 is preferably circular as illustrated inFIG. 2. The diameter of base 12 is preferably from about 2.5 to 20.0 cm(1.0 to 8.0 in), although smaller and larger bases are alsocontemplated. Base shapes other than circular are contemplated,including, but not limited to, oval, rectangular, square, triangular,diamond, and other polygonal shapes, as are relatively rigid orinflexible bases.

Preferably, the base 12 is molded integral with the bristles 18 toprovide a unitary abrasive brush. Thus, no adhesive or mechanical meansis required to adhere the bristles 18 to the base 12. It is preferredthat the base 12 and bristles 18 are molded simultaneously. In someinstances, there may be a single mixture of abrasive particles 26 andmoldable polymer 28 that is placed in the mold in a single injectionprocess. In such an embodiment, the abrasive brush 10 comprises agenerally homogenous composition throughout. However, due to the moldingprocess, the abrasive particle/binder mix may not be perfectlyhomogeneous. For example, as the polymer and abrasive mix is injectedinto the mold, the effects of the narrow bristle cavities may be tocause more polymer to initially cool adjacent the inside of the bristlecavity near the base, forcing a mix having a somewhat higherconcentration of abrasive particles toward the tip 22 of the bristle.

Alternatively, there may be two or more insertions of a moldable polymer28 to the mold. For example, one insertion may contain a mixture ofmoldable polymer 28 and abrasive particles 26. This mixture is primarilylocated in the bristles 18. A second insertion may contain moldablepolymer 28 without abrasive particles 26, or with fewer abrasiveparticles. The moldable polymer 28 without abrasive particles would bepresent primarily in the base 12 of the abrasive brush 10.

It is also within the scope of this invention to have two insertions,both containing abrasive particles. The first insertion may have largerabrasive particles, while the second insertion may have smaller and/orsofter abrasive particles. During abrading, the coarse abrasiveparticles are used and then the finer abrasive particles are used.

Bristles

The bristles 18 extend from the first side 14 of base 12, with root 20adjacent the base 12 and tip 22 remote from the base 12. The bristles 18may have any cross sectional area, including but not limited to,circular, star, half moon, quarter moon, oval, rectangular, square,triangular, diamond or polygonal. In one preferred embodiment, thebristles 18 comprise a constant circular cross section along the lengthof the bristle 18. In other preferred embodiments, the bristles 18 willhave a non-constant or variable cross section along all or a portion ofthe length of the bristle.

It is preferred to have tapered bristles such that the cross sectionalarea of the bristle decreases in the direction away from base 12.Tapered bristles 18 can have any cross section as described above, andpreferably have a circular cross section. Tapered bristles 18 tend to beeasier to remove from the mold during fabrication of the abrasive brushthan constant cross sectional area bristles 18. Furthermore, bristles 18are subjected to bending stresses as abrasive brash 10 is rotatedagainst a workpiece as illustrated in FIG. 3. These bending stresses arehighest at the root 20 of bristles 18. Therefore, a tapered bristle suchas illustrated in FIGS. 4 and 5 is more able to resist bending stressesthan a cylindrical bristle 18. Furthermore, brush 10 preferably includesa fillet radius 24 at the transition between the root 20 of the bristle18 and the first surface 14 of the base. Fillet 24 can have a radius offrom about 0.25 to 2.5 mm (0.010 to 0.100 in), and more preferably fromabout 0.5 to 1.3 mm (0.020 to 0.050 in). In one preferred embodimentillustrated in FIG. 4, bristles 18 are conical, having a decreasingdiameter along the entire length. In another preferred embodimentillustrated in FIG. 5, bristles 18 have a tapered portion adjacent thebase and a cylindrical portion for the remainder of the bristle. In onepreferred embodiment, the taper extends from root 20 to approximately80% of the length towards the tip 22, and the bristle is cylindrical forthe remainder of the length to tip 22. The taper can comprise anysuitable angle, and in one preferred embodiment is approximately 3° asmeasured at angle α in FIGS. 4 and 5.

Bristles 18 comprise an aspect ratio defined as the length of bristle 18measured from root 20 to tip 22, divided by the width of the bristle. Inthe case of a tapered bristle, the width is defined as the average widthalong the length for purposes of determining the aspect ratio. In thecase of non-circular cross section, the width is taken as the longestwidth in a given plane, such as the corner-to-corner diagonal of asquare cross section. The aspect ratio of bristles 18 is preferably atleast 1, more preferably from about 4 to 18, and still more preferablyfrom about 6 to 16. The size of bristles 18 can be selected for theparticular application of brash 10. The length of the bristles 18 ispreferably from about 5 to 80 mm, more preferably from about 5 to 50 mm,still more preferably from about 5 to 25 mm, and most preferably fromabout 10 to 20 mm. The width of the bristles 18 is preferably from about0.25 to 10 mm, more preferably from about 0.5 to 5.0 mm, still morepreferably about 0.75 to 3.0 mm, and most preferably from about 1.0 to2.0 mm. In one preferred embodiment, all of the bristles 18 have thesame dimensions. Alternatively, bristles 18 on a single brush 10 mayhave different dimensions such as different lengths, widths or crosssectional areas. The lengths of the bristles 18 and contour of the base12 are preferably chosen so that the tips 22 are generally coplanar,although other arrangements are also contemplated by the presentinvention.

The density and arrangement of the bristles 18 can be chosen for theparticular application of abrasive brush 10. The bristles 18 may bearranged on the base 12 in a random or ordered pattern. If the base 12is circular, it is preferred to have the bristles 18 arranged inconcentric circular rings. As abrasive brush 10 is rotated to treat aworkpiece, those bristles near the center of the base 12 travel at aslower linear speed than the bristles 18 near the periphery of the base12. Therefore, bristles 18 at or near the center of the base 12 would doless work relative to the bristles 18 remote from the center.Accordingly, brush 10 may have a portion of first face 14 at the centerof base 12 which does not include any bristles 18 as illustrated in FIG.2. The bristles 18 may or may not abut adjacent bristles as desired. Thedensity of bristles 18 preferably ranges from about 5 to 30bristles/cm², more preferably from about 10 to 25 bristles/cm², stillmore preferably from about 15 to 20 bristles/cm² and most preferablyabout 20 bristles/cm². The bristles may be present over only a portionof first side 14 of base 12, or substantially the entire first side 14of base 12.

The material, length, and configuration of the bristles are preferablychosen such that bristles 18 are sufficiently flexible to aid inrefining uneven or irregular workpieces. The bristles 18 are preferablycapable of bending at least 10°, more preferably at least 25°, stillmore preferably at least 45°, and most preferably at least 90°, withoutdamage or substantial permanent deformation to the bristles. Preferably,base 12 is also flexible to further aid in refining such workpieces.When flexible bristles are used, the bristle contacts the workpiecesurface at the juncture of the leading edge of the tip 22 and theoutermost portion of the side surface of the bristle, as illustrated atA in FIG. 3. This is in contrast to inflexible abrading protrusionshaving very low aspect ratios, as known in the art. Such protrusionsprimarily contact the workpiece with the entire planar surface at thetip of the protrusion.

In one preferred embodiment, bristles 18 are of equal length and extendfrom a planar base 12, resulting in the tips 22 being coplanar when thebrush is at rest. It is also possible to have base 12 and bristle 18arrangements in which the tips 22 of the bristles are not coplanar. Forexample, it is possible to have bristles near the periphery of the basebe longer than the bristles at the center of the brush 10. This can bedone to compensate for the deformation of the bristles caused by highrotational speed (as high as 22,000 RPM or more). Under such conditions,the bristles near the periphery of the base 12 travel at a higher speedthan the bristles near the center of the base, and thus bend radiallyoutwardly to a greater extent than the bristles near the center of thebase. The at-rest height variation can be selected so as to achieveapproximately coplanar bristle tips 22 at operating conditions.

Attachment Means

Referring to FIG. 1, abrasive brush 10 comprises attachment means 30integral with base 12. The attachment means 30 provides a means tosecure the abrasive brush 10 to a rotary tool and/or a support pad or aback up pad during use. It is preferred that the attachment means 30 ismolded integrally with the base and bristles. Preferred attachment meansare described in U.S. Pat. Nos. 3,562,968; 3,667,170; and 3,270,467 theentire disclosures of all of which are incorporated herein by reference.Most preferred is the integrally-molded threaded stud adapted forscrew-type engagement with a rotary tool as taught by U.S. Pat. No.3,562,968. This type of attachment means is preferred for circular ordisc shaped brush 10. It is preferred that the attachment means 30 becentered relative to the base 12 for proper rotation. The attachmentmeans 30 may be made from the same material as the rest of the abrasivebrush 10, and may contain abrasive particles 26. Alternatively, theattachment means 30 may be made from a separate injection of moldablepolymer 28 without abrasive particles 26.

It is also within the scope of this invention to use a hook and looptype attachment such as that taught in U.S. Pat. No. 5,077,870,"Mushroom-Type Hook Strip for a Mechanical Fastener," (Melbye et al.) orof the type commercially available as SCOTCHMATE™ from Minnesota Miningand Manufacturing Company, St. Paul, Minn. It is also possible to use ahermaphroditic fastener such as DUAL LOCK™ fastener, available fromMinnesota Mining and Manufacturing Company, to secure the abrasive brushto a back up pad. It is also possible to employ intermeshing structuredsurfaces such as taught in U.S. Pat. No. 4,875,529, "IntermeshingArticles" (Appeldorn), the entire disclosure of which is incorporatedherein by reference. Alternatively, the base of the abrasive brush maycontain one or more straight or threaded holes or openings so that theabrasive brush may be mechanically secured (such as with a bolt and nut)to the back up pad.

Reinforcing Means

The base portion may further comprise reinforcing means which cancomprise a fiber reinforcing means 40a as illustrated in FIG. 6.Reinforcing means 40a can comprise, for example, fabric, non-wovensheeting, mesh, scrim, and the like, or can comprise individual fiberscompounded into the moldable polymer and dispersed throughout theabrasive brush. The purpose of the reinforcing means is to increase theflexural strength and tensile strength of the backing. Examples ofreinforcing fibers suitable for use in the present invention includeglass fibers, metal fibers, carbon fibers, wire mesh, mineral fibers,fibers formed of heat resistant organic materials, or fibers made fromceramic materials. Other organic fibers include polyvinyl alcoholfibers, nylon fibers, polyester fibers and phenolic fibers. Glass fibersmay preferably contain a coupling agent, such as a silane couplingagent, to improve the adhesion to the thermoplastic material. The lengthof the fiber will range from about 0.5 mm to about 50 mm, preferablyabout 1 mm to about 25 mm, most preferably about 1.5 mm to about 10 mm.The fiber denier will be between about 25 to 300, preferably between 50to 200.

The reinforcing means may comprise a reinforcing layer or substrate 40bas illustrated in FIG. 7. Abrasive brush 10 comprises base 12 havingattached to it on second side 16 a reinforcing substrate 40b. Thepurpose of the reinforcing substrate 40b is to increase the strength ofthe base 12. The reinforcing substrate 40b can be free of abrasiveparticles 26. It is not necessary to include abrasive particles in thislayer, since the reinforcing substrate 40b does not contact theworkpiece. The reinforcing substrate can comprise a moldable polymer. Inthis case, the reinforcing substrate can be molded at the same time asthe abrasive brush 10. Alternatively, the reinforcing substrate 40b canbe a backing type material such as a polymeric film, primed polymericfilm, cloth, paper, vulcanized fiber, nonwoven layer, and treatedversions thereof. In this case, the reinforcing substrate 40b can beinserted into the mold and the moldable polymer 28 forming the brush 10can bond to the reinforcing substrate 40b. Alternatively, thereinforcing substrate 40b can be adhesively bonded to the brush 10 afterthe brush is molded. In one preferred embodiment, the reinforcingsubstrate 40b is coextensive with the base 12, although it may besmaller or larger as desired.

Moldable Polymer

The moldable polymer material 28 is preferably an organic bindermaterial that is capable of being molded, i.e., it is capable ofdeforming under heat to form a desired shape. The moldable polymer maybe a thermoplastic polymer, a thermosetting polymer, or a thermoplasticelastomer. In the case of a thermoplastic polymer, the organic binder isheated above its melting point which causes the polymer to flow. Thisresults in the thermoplastic polymer flowing into the cavities of themold to form the abrasive brush 10. The abrasive brush is then cooled tosolidify the thermoplastic binder. In the case of a thermosettingpolymer, during molding the organic binder is in a thermoplastic state,i.e., after it is heated above its melting point it will flow into thecavities of the mold to form the abrasive brush. Next, the abrasivebrush is further heated, in some instances at a higher temperature, tocause this organic binder to crosslink and form a thermosetting polymer.Examples of suitable thermosetting polymers include styrene butadienerubber, polyurethane, urea-formaldehyde, epoxy, and phenolics.

Thermoplastic Polymers

The abrasive brush according to the present invention may comprise athermoplastic polymer. Examples of suitable thermoplastic polymersinclude polycarbonate, polyetherimide, polyester, polyethylene,polysulfone, polystyrene, polybutyIene, acrylonitrile-butadiene-styreneblock copolymer, polypropylene, acetal polymers, polyurethanes,polyamides, and combinations thereof. In general, preferredthermoplastic polymers of the invention are those having a high meltingtemperature and good heat resistance properties. Thermoplastic polymersmay be preferably employed for low speed applications of abrasive brush10, in which stress during operation is relatively low. Examples ofcommercially available thermoplastic polymers suitable for use with thepresent invention include Grilon™ CR9 copolymer of Nylon 6,12 availablefrom EMS-American Grilon, Inc., Sumter S.C.; Profax™ and KS075polypropylene based thermoplastic available from Himont USA, Inc.,Wilmington, Del.; and Duraflex™ polybutylene based thermoplasticavailable from Shell Chemical Co., Houston, Tex.

Thermoplastic Elastomers

In some instances, such as high speed, high stress applications, it ispreferred that the moldable polymer is a thermoplastic elastomer orincludes a thermoplastic elastomer. Thermoplastic elastomers (or "TPE"s)are defined and reviewed in Thermoplastic Elastomers, A ComprehensiveReview, edited by N. R. Legge, G. Holden and H. E. Schroeder, HanserPublishers, New York, 1987 (referred to herein as "Legge et al.", theentire disclosure of which is incorporated by reference herein).Thermoplastic elastomers (as used herein) are generally the reactionproduct of a low equivalent weight polyfunctional monomer and a highequivalent weight polyfunctional monomer, wherein the low equivalentweight polyfunctional monomer has a functionality of at most about 2 andequivalent weight of at most about 300 and is capable on polymerizationof forming a hard segment (and, in conjunction with other hard segments,crystalline hard regions or domains) and the high equivalent weightpolyfunctional monomer has a functionality of at least about 2 and anequivalent weight of at least about 350 and is capable on polymerizationof producing soft, flexible chains connecting the hard regions ordomains.

"Thermoplastic elastomers" differ from "thermoplastics" and "elastomers"(a generic term for substances emulating natural rubber in that theystretch under tension, have a high tensile strength, retract rapidly,and substantially recover their original dimensions) in thatthermoplastic elastomers, upon heating above the melting temperature ofthe hard regions, form a homogeneous melt which can be processed bythermoplastic techniques (unlike elastomers), such as injection molding,extrusion, blow molding, and the like. Subsequent cooling leads again tosegregation of hard and soft regions resulting in a material havingelastomeric properties, however, which does not occur withthermoplastics. Thermoplastic elastomers combine the processability(when molten) of thermoplastic materials with the functional performanceand properties of conventional thermosetting rubbers (when in theirnon-molten state), and which are described in the art as ionomeric,segmented, or segmented ionomeric thermoplastic elastomers. Thesegmented versions comprise "hard segments" which associate to formcrystalline hard domains connected together by "soft", long, flexiblepolymeric chains. The hard domain has a melting or disassociationtemperature above the melting temperature of the soft polymeric chains.

Commercially available thermoplastic elastomers include segmentedpolyester thermoplastic elastomers, segmented polyurethane thermoplasticelastomers, segmented polyamide thermoplastic elastomers, blends ofthermoplastic elastomers and thermoplastic polymers, and ionomericthermoplastic elastomers.

"Segmented thermoplastic elastomer", as used herein, refers to thesub-class of thermoplastic elastomers which are based on polymers whichare the reaction product of a high equivalent weight polyfunctionalmonomer and a low equivalent weight polyfunctional monomer. Segmentedthermoplastic elastomers are preferably the condensation reactionproduct of a high equivalent weight polyfunctional monomer having anaverage functionality of at least 2 and an equivalent weight of at leastabout 350, and a low equivalent weight polyfunctional monomer having anaverage functionality of at least about 2 and an equivalent weight ofless than about 300. The high equivalent weight polyfunctional monomeris capable on polymerization of forming a soft segment, and the lowequivalent weight polyfunctional monomer is capable on polymerization offorming a hard segment. Segmented thermoplastic elastomers useful in thepresent invention include polyester TPEs, polyurethane TPEs, andpolyamide TPEs, and silicone elastomer/polyimide block copolymeric TPEs,with the low and high equivalent weight polyfunctional monomers selectedappropriately to produce the respective TPE.

The segmented TPEs preferably include "chain extenders", low molecularweight (typically having an equivalent weight less than 300) compoundshaving from about 2 to 8 active hydrogen functionality, and which areknown in the TPE art. Particularly preferred examples include ethylenediamine and 1,4-butanediol.

"Ionomeric thermoplastic elastomers" refers to a sub-class ofthermoplastic elastomers based on ionic polymers (ionomers). Ionomericthermoplastic elastomers are composed of two or more flexible polymericchains bound together at a plurality of positions by ionic associationsor clusters. The ionomers are typically prepared by copolymerization ofa functionalized monomer with an olefinic unsaturated monomer, or directfunctionalization of a preformed polymer. Carboxyl-functionalizedionomers are obtained by direct copolymerization of acrylic ormethacrylic acid with ethylene, styrene and similar comonomers byfree-radical copolymerization. The resulting copolymer is generallyavailable as the free acid, which can be neutralized to the degreedesired with metal hydroxides, metal acetates, and similar salts. Areview of ionomer history and patents concerning same is provided inLegge et al., pp. 231-243.

"Thermoplastic polymer", or "TP" as used herein, has a more limitingdefinition than the general definition, which is "a material whichsoftens and flows upon application of pressure and heat." It will ofcourse be realized that TPEs meet the general definition of TP, sinceTPEs will also flow upon application of pressure and heat. It is thusnecessary to be more specific in the definition of "thermoplastic" forthe purposes of this invention. "Thermoplastic", as used herein, means amaterial which flows upon application of pressure and heat, but whichdoes not possess the elastic properties of an elastomer when below itsmelting temperature.

Blends of TPE and TP materials are also within the invention, allowingeven greater flexibility in tailoring mechanical properties of theabrasive filaments of the invention.

Commercially available and preferred segmented polyesters include thoseknown under the trade designations "Hytrel™ 4056", "Hytrel™ 5526","Hytrel™ 5556", "Hytrel™ 6356", "Hytrel™ 7246", and "Hytrel™ 8238"available from E. I. Du Pont de Nemours and Company, Inc., Wilmington,Del., with the most preferred including Hytrel™ 5526, Hytrel™ 5556, andHytrel™ 6356. A similar family of thermoplastic polyesters is availableunder the tradename "Riteflex" (Hoechst Celanese Corporation). Stillfurther useful polyester TPEs are those known under the tradedesignations "Ecdel", from Eastman Chemical Products, Inc., Kingsport,Tenn.; "Lomad", from General Electric Company, Pittsfield, Mass.;"Arnitel" from DSM Engineered Plastics; and "Bexloy" from Du Pont.Further useful polyester TPEs include those available as "Lubricomp"from LNP Engineering Plastics, Exton, Pa., and is commercially availableincorporating lubricant, glass fiber reinforcement, and carbon fiberreinforcement.

Commercially available and preferred segmented polyamides include thoseknown under the trade designation "Pebax" and "Rilsan", both availablefrom Atochem Inc., Glen Rock, N.J.

Commercially available and preferred segmented polyurethanes includethose known under the trade designation "Estane", available from B. F.Goodrich, Cleveland, Ohio. Other segmented preferred segmentedpolyurethanes include those known under the trade designations"Pellethane", and "Isoplast" from The Dow Coming Company, Midland,Mich., and those known under the trade designation "Morthane", fromMorton Chemical Division, Morton Thiokol, Inc.; and those known underthe trade designation "Elastollan", from BASF Corporation, Wyandotte,Mich.

Thermoplastic elastomers are further described in U.S. patentapplication Ser. No. 08/351,884, filed Dec. 6, 1994, and assigned to theassignee of the present application, the entire disclosure of which isincorporated herein by reference.

Abrasive Particles

The abrasive particles 26 typically have a particle size ranging fromabout 0.1 to 1500 micrometers, usually between about 1 to 1300micrometers, and preferably between 50 and 500 micrometers. The abrasiveparticles may be organic or inorganic. Examples of abrasive particlesinclude fused aluminum oxide, ceramic aluminum oxide, heated treatedaluminum oxide, silicon carbide, titanium diboride, alumina zirconia,diamond, boron carbide, ceria, cubic boron nitride, and garnet. Stillother examples of abrasive particles include solid glass spheres, hollowglass spheres, calcium carbonate, polymeric bubbles, silicates, aluminumtrihydrate, and mullite. Preferred ceramic aluminum oxide abrasiveparticles include those described in U.S. Pat. Nos. 4,314,827;4,623,364; 4,744,802; 4,770,671; 4,881,951; and 4,964,883, the contentsof all of which are incorporated herein by reference. The abrasiveparticle can be any particulate material (inorganic or organic) thatwhen combined with the binder results in an abrasive brush 10 that canrefine a workpiece surface. The selection of the abrasive material willdepend in part on the intended application. For example, for strippingpaints from a vehicle, it is sometimes preferred to use a relativelysoft abrasive particle so as not to damage the surface underneath thepaint. Alternatively, for removing burs from metal workpieces, it ispreferred to use a harder abrasive particle such as alumina. Theabrasive brush of the present invention may include two or more typesand/or sizes of abrasive particles.

As used herein, the term abrasive particles also encompasses singleabrasive particles which are bonded together to form an abrasiveagglomerate. Abrasive agglomerates are further described in U.S. Pat.Nos. 4,311,489; 4,652,275; and 4,799,939, the disclosures of all ofwhich are incorporated herein by reference. The abrasive particles ofthis invention may also contain a surface coating. Surface coatings areknown to improve the adhesion between the abrasive particle and thebinder in the abrasive article. Such surface coatings are described inU.S. Pat. Nos. 5,011,508; 1,910,444; 3,041,156; 5,009,675; 4,997,461;5,213,591; and 5,042,991, the disclosures of all of which areincorporated herein by reference. In some instances, the addition of thecoating improves the abrading and/or processing characteristics of theabrasive particle.

Organic abrasive particles suitable for use with the abrasive brush ofthe present invention include polyester, polyvinylchloride,methacrylate, methylmethacrylate, polycarbonate, polystyrene andthermoset polymeric particles such as phenolic particles andurea-formaldehyde particles. A preferred organic abrasive particle is ametal and mold cleaning plastic blast media available commercially as"MC" blast media from Maxi Blast Inc., South Bend, Indiana, availablewith an antistatic coating, but preferably untreated. The "MC" media isa 99% melamine formaldehyde cellulosate, an amino thermoset plastic.

The abrasive particles 26 are preferably from about 5 to 60 percent byweight of the particle and polymer mixture, and more preferably about 30to 40 percent, although more or less may be used as desired.

Additives

The moldable polymeric material 28 may further include optionaladditives, such as, for example, fillers (including grinding aids),fibers, antistatic agents, antioxidants, processing aids, UVstabilizers, flame retardants, lubricants, wetting agents, surfactants,pigments, dyes, coupling agents, plasticizers and suspending agents. Theamounts of these materials are selected to provide the propertiesdesired.

Lubricants

For some refining applications, it is preferred that the molded polymer28 include a lubricant. The presence of a lubricant in the moldablepolymer 28 reduces the friction of the bristle contacting the workpiecesurface. This reduces the heat generated when refining the workpiece.Excessive heat may cause the abrasive brush to leave residue on theworkpiece or to otherwise harm the workpiece. Suitable lubricantsinclude lithium stearate, zinc stearate, calcium stearate, aluminumstearate, ethylene bis stearamide, graphite, molybdenum disulfide,polytetraflouroethylene (PTFE), and silicone compounds, for exampleuseful with thermoplastics and thermoplastic elastomers.

An example of a preferred silicone material, which is described in U.S.patent application Ser. No. 08/430,477; entitled "Abrasive ArticleHaving a Bond System Comprising a Polysiloxane" (Barber), (attorneydocket number 51579USA8A) filed on even date herewith, the descriptionof the silicone material being incorporated herein by reference, is ahigh molecular weight polysiloxane of formula (A): ##STR1## wherein R,R', R¹, R², R³, R⁴, R⁵, and R⁶ may be the same or different and can bean alkyl, vinyl, chloroalkyl, aminoalkyl, epoxy, fluororalkyl, chloro,fluoro, or hydroxy, and n is 500 or greater, preferably 1,000 orgreater, more preferably 1,000 to 20,000, and most preferably 1,000 to15,000.

Another preferred polysiloxane is a polydimethylsiloxane of formula (B):##STR2## wherein R and R' may be the same or different and can be analkyl, vinyl, chloroalkyl, aminoalkyl, epoxy, fluororalkyl, chloro,fluoro, or hydroxy, and n is 500 or greater, preferably 1,000 orgreater, more preferably 1,000 to 20,000, and most preferably 1,000 to15,000.

Polysiloxanes are available in many different forms, e.g., as thecompound itself or as a concentrate. Example of the polymers into whichthe polysiloxane can be compounded include polypropylene, polyethylene,polystyrene, polyamides, polyacetal, acrylonitrile-butadiene-styrene(ABS), and polyester elastomer, all of which are commercially available.Silicone modified Hytrel™ is available commercially as BY27-010 (orMB50-010), and silicone modified Nylon 6,6 is available commercially asBY27-005, both from Dow Coming Company, Midland, Mich. Typically,commercially available concentrates may contain a polysiloxane at aweight percent ranging from 40 to 50; however, any weight percent isacceptable for purposes of the invention as long as the desired weightpercent in the final product can be achieved. Lubricants preferably canbe present in the moldable polymer 26 in amounts of up to about 20percent by weight (exclusive of abrasive particle content), andpreferably in an amount from about 1 to 10 percent, although more orless may be used as desired.

Coupling Agent

The moldable polymeric material 28 may include a coupling agent toimprove the bond between the binder and the abrasive particles as isknown in the art. Examples of such coupling agents suitable for thisinvention include organo silanes, zircoaluminates and titanates. Theabrasive particles 26 may be pretreated with a coupling agent prior tobeing with the moldable polymer. Alternatively, the coupling agent maybe added directly to the moldable polymer 28.

Fillers

The moldable polymeric material 28 may include a filler as is known inthe art. Examples of useful fillers for this invention include: metalcarbonates (such as calcium carbonate (chalk, calcite, marl, travertine,marble and limestone), calcium magnesium carbonate, sodium carbonate,magnesium carbonate), silica (such as quartz, glass beads, glass bubblesand glass fibers) silicates (such as talc, clays, (montmorillonite)feldspar, mica, calcium silicate, calcium metasilicate, sodiumaluminosilicate, sodium silicate) metal sulfates (such as calciumsulfate, barium sulfate, sodium sulfate, aluminum sodium sulfate,aluminum sulfate), gypsum, vermiculite, wood flour, aluminum trihydrate,carbon black, metal oxides (such as calcium oxide (lime), aluminumoxide, titanium dioxide) and metal sulfites (such as calcium sulfite).

Grinding Aids

The polymeric material may include a grinding aid. A grinding aid isdefined herein as particulate material that the addition of which has asignificant effect on the chemical and physical processes of abradingwhich results in improved performance. In particular, it is believed inthe art that the grinding aid will either 1) decrease the frictionbetween the abrasive particles and the workpiece being abraded, 2)prevent the abrasive particle from "capping", i.e. prevent metalparticles from becoming welded to the tops of the abrasive particles, 3)decrease the interface temperature between the abrasive particles theworkpiece, or 4) decreases the grinding forces. Examples of chemicalgroups of grinding aids include waxes, organic halide compounds, halidesalts and metals and their alloys. The organic halide compounds willtypically break down during abrading and release a halogen acid or agaseous halide compound. Examples of such materials include chlorinatedwaxes like tetrachloronaphthalene, pentachloronaphthalene; and polyvinylchloride. Examples of halide salts include sodium chloride, potassiumcryolite, sodium cryolite, ammonium cryolite, potassiumtetrafluoroborate, sodium tetrafluoroborate, silicon fluorides,potassium chloride, magnesium chloride. Examples of metals include, tin,lead, bismuth, cobalt, antimony, cadmium, iron, and titanium. Othermiscellaneous grinding aids include sulfur, organic sulfur compounds,graphite and metallic sulfides.

Injection Molding

The abrasive brush of the present invention is preferably injectionmolded. The mold will contain cavities which are the inverse of thedesired abrasive brush configuration. Thus the mold design must takeinto account the abrasive brush configuration including the size andconfiguration of the base 12, the bristles 18, and the optionalattachment means 30.

Injection molding techniques are known in the art. Injection moldingapparatus 60 for making the abrasive brush 10 according to the method ofthe present invention is illustrated in FIG. 8. After preferably beingdried by heating, a mixture of pellets comprising moldable polymer 28and abrasive particles 26 is placed in a hopper 62. The hopper feeds themixture into a first or rear side 70 of a screw injector 64 generallycomprising a screw 66 within a barrel 68. The opposite side, or frontside 72 of the screw injector 64 comprises a nozzle 74 for passing thesoftened mixture into a mold 76a, 76b. The barrel 68 of the injector 64is heated to melt the mixture, and the rotating screw 66 propels themixture in the direction of the nozzle 74. The screw 66 is then movedlinearly frontward in direction B to impart the "shot" of the softenedmixture into the mold 76a, 76b at the desired pressure. A gap isgenerally maintained between the forward end of the screw and the nozzleto provide a "cushion" area of softened material which is not injectedinto the mold.

The above mentioned pellets can be preferably prepared as follows. Themoldable polymer 28 can be heated above its melting point and theabrasive particles 26 can then be mixed in. The resulting mixture isthen formed into continuous strands and the strands are cooled tosolidify the moldable polymer for pelletizing on suitable equipment asis known in the art. Likewise, lubricants and/or other additives to thepolymeric material 28 can be included in the formation of the pellets.The pellets comprising the moldable polymer 28, abrasive particles 26,and any desired lubricant or other additive are then placed into thehopper 62 to be fed into the screw extruder 64 as described above.Alternatively, it is possible to mix the abrasive particles 26 withpellet form of the moldable polymer 28 and load this in the hopper.Likewise, lubricants and/or other additives to the polymeric material 28can be mixed in prior to being loaded into the hopper.

The conditions under which the abrasive brush is injection molded aredetermined by the injection molder employed, the configuration of thebrush 10, and the composition of the moldable polymer 28 and abrasiveparticles 26. In one preferred method, the moldable polymer 28 is firstheated to between 80° to 120° C., preferably 90° to 110° C. for drying,and is placed in the hopper 62 to be gravity fed into the screw feedzone. The barrel temperature of the screw injector is preferably fromabout 200° to 250° C., more preferably from about 220° to 245° C. Thetemperature of the mold is preferably from about 50° to 150° C., morepreferably from about 100° to 140° C. The cycle time (the time fromintroducing the mixture into the screw extruder to opening the mold toremove the molded abrasive brush) will preferably range between 0.5 to180 seconds, more preferably from about 5 to 60 seconds. The injectionpressure will preferably range from about 690 to 6,900 kPa (100 to 1000psi), more preferably from about 2070 to 4830 kPa (300 to 700 psi).

The injection mold cycle will depend upon the material composition andthe abrasive brush configuration. In one preferred embodiment, themoldable polymer and abrasive particles are generally homogenousthroughout the abrasive brush 10. In such an embodiment, there will be asingle insertion or shot of mixture of the polymeric material 28 andabrasive particle 26 to mold the brush 10, including the base 12,bristles 18, and attachment means 30 if present. Alternatively, thebristles 18 may contain abrasive particles 26, but the base 12 does not.In such an embodiment, there will be two insertions or shots ofmaterial. The first insertion will contain a mixture of moldable polymer28 and abrasive particles 26 to primarily fill the bristle portion ofthe mold. The second insertion will contain moldable polymer (which maybe the same or different from the moldable polymer of the firstinsertion) without abrasive particles to primarily fill the base andattachment means portions of the mold. Likewise, the base 12 andbristles 18 may contain abrasive particles, but the attachment means 30may not. In this construction there will be two insertions or shot ofmaterial. The first insertion will contain a mixture of moldable polymer28 and abrasive particles 26 to fill the bristle and base portions ofthe mold. The second insertion will contain only a moldable polymer(which may be the same or different from the moldable polymer of thefirst insertion) to primarily fill the attachment means portion of themold. It is also possible to use more than one shot to vary the color ofdifferent portions of the brush if desired. It is also possible toemploy three or more shots, for example one each for the bristles, base,and attachment means. After injection molding, the mold is rapidlycooled to solidify the moldable polymer. The mold halves 76a and 76b arethen separated to allow removal of molded abrasive brush 10.

Preferably, an ejector assembly 80 is provided on the opposite side ofmold 76a, 76b from the injection port to eject the solidified abrasivebrush 10 from the mold. As seen in FIG. 9, ejector pins 82 arepreferably located in each mold cavity 78 which corresponds to a bristle18. After the abrasive brush 10 is sufficiently cooled and mold portion76a has been removed, tips 84 of ejector pins 82 are forced to moveagainst the tip 22 of the bristle in direction C towards the base 12, tothereby eject the bristles 18 from their respective cavities. In onepreferred embodiment, the location of the tips 84 of ejector pins 82within the cavity is variable, thereby varying the depth of the moldcavity 78 allowing for longer or shorter bristles 18 to be molded. Thiscan be done by varying the position of ejector 80 relative to moldportion 76b, or by varying the length of the ejector pins 82 on theejector 80.

Method of Refining a Surface

As discussed above, the molded abrasive brush 10 according to thepresent invention is used to refine a surface by: removing a portion ofa workpiece surface; imparting a surface finish to a workpiece; cleaninga workpiece surface, including removing paint or other coatings, gasketmaterial, corrosion, or other foreign material; or some combination ofthe foregoing. The abrasive brush 10 is fastened by the attachment meansto a suitable power rotary tool, and is particularly well adapted foruse with right angle power tools as are known in the art. One suitablepower tool for use the molded abrasive brush according to the presentinvention is the Ingersoll-Rand cyclone series right angle grinder,model TA 180 RG4, rated at 18,000 rpm and 0.70 hp. The molded abrasivebrush 10 may mounted by itself on the rotary power tool, or may employ aback-up pad behind the abrasive brush 10 as is known in the art. Onesuitable back-up pad arrangement is that disclosed in to U.S. Pat. No.3,562,968 (Johnson et al.), the entire disclosure of which isincorporated herein by reference.

Referring now to FIGS. 11 and 12, there is seen an alternate embodimentof molded abrasive brush 110 according to the present invention.Abrasive brush 110 comprises planar base 112 which is a generallywedge-shaped polygon as shown. Base 112 has first side 114 and secondside 116 opposite one another. Extending from first side 114 are aplurality of bristles 118. Bristles 118 may be tapered to have root 120wider than tip 122 for all or a portion of the length of bristles 118 asdescribed above with respect to the embodiment of FIGS. 1 and 2.

While abrasive brush 110 is configured for convenient use with rotaryfloor machines commonly used in floor maintenance procedures, itsutility is not thereby limited. As seen in FIG. 13, a plurality ofabrasive brushes 110 may be mounted on a suitable backing 140 to formassembly 150. Suitable backings 140 include those available commerciallyas INSTA LOK™ drive assembly from Minnesota Mining and ManufacturingCompany, St. Paul, Minn., which have been modified to have abrasivebrushes 110 mounted thereon as described below. Backing 140 may beattached to rotary floor machines as is known in the art for refining afloor surface.

Preferably, abrasive brushes 110 are generally wedge-shaped and arearranged on backing 140 so as to have gaps therebetween where firstsurface 142 of backing 140 has no bristles 118. Abrasive brushes 110 maybe preferably arranged in a substantially equal angular spacing aroundthe backing 140. The segmented arrangement of bristles 118 and abrasivebrushes 110 on backing 140 in combination with the generally parallelbristles 118 creates a series of "edges" which may allow the bristles118 to reach recesses in an uneven surface, thus providing a treatmentefficiency greater than a similar brush assembly without a segmentedtreatment surface. The segmented arrangement also aids in reducing theamount of material which accumulates in the bristles 118. The open areasbetween brushes 110 provide space for material to accumulate and therebylengthen the service life of the abrasive brush 110. The gaps alsoreduce the number of bristles 118 on a given backing 140 which resultsin an increased pressure on the remaining bristles 118 during operation.The remaining bristles 118 must each support a greater force, and theresultant increase in pressure at the tips 122 of the bristles 118further aids in improving the treatment efficiency of the inventivebrush assembly. Alternatively, brushes 110 may be arranged to provide anuninterrupted arrangement of bristles 118 on backing 140. Or, a singlebrush 110 may be provided with a circular backing 112 conforminggenerally to the size of backing 140.

Abrasive brush 110 may comprise any of the moldable polymers 128,additives, and abrasive particles 126 as described above with referenceto the embodiments of FIGS. 1-9. Abrasive brush 110 may omit abrasiveparticles 126. For applications such as floor scrubbing and polishing,one suitable moldable polymer 128 comprises polyester-based TPE such asis commercially available as Hytrel™ 5526 from E. I. Du Pont de Nemours,Wilmington Del., and 30% by weight 120 grade silicon carbide as abrasiveparticles 126.

It is possible to employ a plurality of like abrasive brushes 110 on anassembly 150. Alternatively, the abrasive brushes 110 may differ withina single assembly 150. For instance, it may be possible to employabrasive brushes 110 having different moldable polymer 128, abrasiveparticles 126, length or arrangement of bristles 118, or any otherparameter. It is also possible to employ bristles 118 having varyingheights within a single abrasive brush 110.

Abrasive brushes 110 may be permanently or removably secured to backing150. As seen in FIG. 14A, second side 116 of brush 110 may be joined tofirst side 142 of backing 140 by adhesive layer 130. Adhesive 130 maycomprise any suitable adhesive including pressure sensitive adhesivesand heat activated adhesives. Alternatively, the materials for abrasivebrush 110 and backing 140 may be chosen to allow attachment by sonicwelding.

Abrasive brush 110 may be mechanically secured to backing 140 by meansof screws, bolts, rivets, clamps or the like. It is also possible toemploy attaching layer 130a on first side 142 of backing 140 andcomplementary attaching layer 132a on second side 116 of abrasive brush110 as illustrated schematically in FIG. 14B. Attachment layers 130a and132a may comprise a hook and loop type attachment system such as thattaught in U.S. Pat. No. 5,077,870, "Mushroom-Type Hook Strip for aMechanical Fastener," (Melbye et al.) or of the type commerciallyavailable as SCOTCHMATE™ from Minnesota Mining and ManufacturingCompany, St. Paul, Minn. It is also possible to use a hermaphroditicfastener such as DUAL LOCK™ fastener, available from Minnesota Miningand Manufacturing Company, to secure the abrasive brush to a back uppad. It is also possible to employ intermeshing structured surfaces suchas taught in U.S. Pat. No. 4,875,529, "Intermeshing Articles"(Appeldorn).

Abrasive brush 110 may be releasably secured to backing 140 by means ofan integrally molded stud 130b extending from second side 116 of backing112 as illustrated in FIG. 14C. Stud 130b is sized and configured toreleasably engage with hole 130b in backing 140. Alternatively, backing140 may comprise slots 130c to slidingly engage rails 132c in backing112 of brush 110 as illustrated in FIG. 14D.

The operation of the present invention will be further described withregard to the following detailed examples. These examples are offered tofurther illustrate the various specific and preferred embodiments andtechniques. It should be understood, however, that many variations andmodifications may be made while remaining within the scope of thepresent invention.

EXAMPLES

The injection molding machine used was a 75 ton Van Dorn single shotextruder with a toggle clamping system, a 54 gram (3 ounce) barrel and ageneral purpose screw.

Molding parameters varied for each example due to formulation changes,mold design, mold condition, screw condition, and barrel condition.Typical molding parameters included: nozzle temperature 232° C. (450°F.), temperature at the from of the barrel (proximate the nozzle) 226°C. (440° F.), temperature at the rear of the barrel (proximate thehopper) 221° C. (430° F.), screw rotation 450 RPM, 2760-3450 kPa(400-500 psi) injection pressure, 5.1 mm (0.200 in) cushion, and a 7.37cm (2.90 in) shot distance or length. A complete cycle time on averagewas about 36 seconds per abrasive brush.

The formulations used for the examples are reported in Table 1. Listedare the polymer components used, and the type and amount of abrasiveparticles. Prior to molding, each of the compounds was dried at 65° C.(150° F.) for 4 hours in a Bryant air dryer. The base 12 of the abrasivebrushes 10 had a diameter of 5 cm (2 in), and a thickness of 2.54 mm(0.1 in.). The abrasive brush 10, had 254 integrally molded bristles 18.Each bristle 18 was 1.27 mm (0.50 in) long and tapered from 2.54 mm(0.10 in) diameter at the root to 1.27 mm (0.05 in) diameter at 80% ofthe length from root 20 to tip 22, and had a diameter of 1.27 mm (0.05in) for the remainder of the length to tip 22. In some abrasive brushes,the fillet radius at the transition from the bristle to the base wasapproximately 0.25 mm (0.01 in) reported as fillet A in Table 2. Otherabrasive brushes had a fillet radius of approximately 0.64 mm (0.025 in)reported as fillet B in Tables 3. Each abrasive brush 10 included anintegrally molded threaded stud as the attachment means 30 according toU.S. Pat. No. 3,562,968 (Johnson et al.).

The following components were used in preparing the examples describedbelow:

    ______________________________________                                        MOLDABLE                                                                      POLYMER:                                                                      Hytrel ™ polyester-based TPE, available from E. I. DuPont                              de Nemours and Company, Inc., Wilmington,                                     Delaware.                                                         Lubricomp ™YL-4030                                                                     polyester based TPE, including 15% PTFE                                       lubricant;                                                        Lubricomp ™YF-1004                                                                     polyester based TPE, including 20% glass fiber                                reinforcement;                                                    Lubricomp ™                                                                            polyester based TPE, including 20% carbon fiber                   YC-1004     reinforcement;                                                                all available from LNP Engineering Plastics, of                               Exton, PA.                                                        Lomad ™Resin B0100                                                                     polyester based TPE available from General                                    Electric Co., of Pittsfield, MA.                                  Estane ™ polyurethane-base TPE available from B. F.                                    Goodrich, Cleveland, Ohio.                                        Pebax ™ 5533 SA 00                                                                     nylon-based TPE, available from Atochem Inc,                                  Glen Rock, New Jersey.                                            Duraflex ™ 0110                                                                        polybutylene TP available from Shell Chemical                                 Co. of Houston, TX.                                               Profax ™KS075P                                                                         polypropylene-based TP;                                           Profax ™KS084P                                                                         polypropylene-based TP, both available from                                   Himont USA Inc. of Wilmington, DE.                                Grilon ™ CR9                                                                           Nylon 6,12 TP, available from EMS-American                                    Grilon, Inc., of Sumter, SC.                                      LUBRICANTS                                                                    BY27-005    polyamide-based polymer melt additive;                            BY27-010 (or                                                                              polyester elastomer-based polymer melt additive;                  MB50-010)   both available from Dow Corning Company,                                      Midland, Michigan.                                                COUPLING AGENTS                                                               silane      silane coupling agent, typically amine functional                             such as gamma-aminopropyltriethoxysilane,                                     available as A-1100, or -1102 from Union                                      Carbide Corporation, New York, NY.                                Z-6030      methacrylate functional silane coupling agent;                    Z-6075      vinyl functional silane coupling agent, both                                  available from Dow Corning Corporation,                                       Midland, Michigan.                                                ABRASIVE                                                                      PARTICLES                                                                     SiC         silicon carbide                                                   Al.sub.2 O.sub.3                                                                          fused aluminum oxide, pretreated by Exolon ESK                                Company, Tonawanda, NY, or Washington Mills                                   Electro Minerals Corp., North Grafton, MA.                        Al.sub.2 O.sub.3 (h)                                                                      heat treated fused aluminum oxide                                 CA01        alpha alumina-based ceramic comprising alpha                                  alumina and a rare earth oxide, commercially                                  available under the designation Cubitron ™ 321                             from Minnesota Mining and Manufacturing                                       Company, St. Paul, MN.                                            CA02        mixture of 15% CA01 and 85% scalped fused                                     alumina                                                           CA03        mixture of 15% CA01 and fused alumina                             CA04        alpha alumina-based ceramic comprising 94.3%                                  alumina, 4.5% aluminum oxide, and 1.2% iron                                   oxide.                                                            MC-3        30/40 mesh size untreated plastic blasting media                              available from Maxi-Blast Company of                                          South Bend, Indiana.                                              ______________________________________                                    

All compositions are reported throughout as weight ratios or percent byweight as the case may be, unless otherwise indicated. The percentcomposition for the components of the moldable polymer is reported basedon 100% for the combination of the components of the moldable polymerexclusive of the abrasive particles. The abrasive content is reported asthe percent composition of the abrasive particles based on 100% for thecombination of the components of the moldable polymer with the abrasiveparticles.

EXAMPLES 1-41

The composition of Examples 1-41 is set forth in Table 1.

                                      TABLE 1                                     __________________________________________________________________________                       Abrasive Particles                                         Moldable Polymer           Coupling                                                                           Abrasive                                      Ex.                                                                              TP and/or TPE                                                                         Lubricant                                                                             Particle                                                                              Agent                                                                              Content                                       __________________________________________________________________________    1  90% CR9 10% BY27-005                                                                          SiC-80 grit                                                                           --   30%                                           2  90% Hytrel 7246                                                                       10% BY27-010                                                                          SiC-80 grit                                                                           --   40%                                           3  90% Hytrel 6356                                                                       10% BY27-010                                                                          SiC-80 grit                                                                           --   40%                                           4  50% Hytrel 7246                                                                       50% YL-4030                                                                           SiC-80 grit                                                                           --   30%                                           5  50% Hytrel 7246                                                                       50% YL-4030                                                                           CA04-80 grit                                                                          --   30%                                           6  84% Hytrel 6356                                                                       16% BY27-010                                                                          Al.sub.2 O.sub.3 -P60 grit                                                            --   30%                                           7.sup.1                                                                          84% Hytrel 6356                                                                       16% BY27-010                                                                          Al.sub.2 O.sub.3 -P60 grit                                                            --   30%                                           8  84% YF-1004                                                                           16% BY27-010                                                                          Al.sub.2 O.sub.3 -P60 grit                                                            --   30%                                           9.sup.1                                                                          84% YF-1004                                                                           16% BY27-010                                                                          Al.sub.2 O.sub.3 -P60 grit                                                            --   30%                                           10 84% Hytrel 6356                                                                       16% BY27-010                                                                          Al.sub.2 O.sub.3 -P120 grit                                                           --   30%                                           11 84% YF-1004                                                                           16% BY27-010                                                                          Al.sub.2 O.sub.3 -P120 grit                                                           --   30%                                           12 84% YF-1004                                                                           16% BY27-010                                                                          CA01-80 grit                                                                          --   30%                                           13.sup.2                                                                         84% YF-1004                                                                           16% BY27-010                                                                          CA01-80 grit                                                                          --   30%                                           14 84% YF-1004                                                                           16% BY27-010                                                                          CA01-120 grit                                                                         --   30%                                           15 84% Hytrel 6356                                                                       16% BY27-010                                                                          CA02-60 grit                                                                          --   30%                                           16.sup.1                                                                         84% Hytrel 6356                                                                       16% BY27-010                                                                          CA02-60 grit                                                                          --   30%                                           17 90% Hytrel 5526                                                                       10% BY27-010                                                                          Al.sub.2 O.sub.3 -80 grit                                                             --   25%                                           18 90% Hytrel 5526                                                                       10% BY27-010                                                                          Al.sub.2 O.sub.3 -80 grit                                                             --   30%                                           19 90% Hytrel 5526                                                                       10% BY27-010                                                                          Al.sub.2 O.sub.3 -80 grit                                                             silane                                                                             25%                                           20 90% Hytrel 5526                                                                       10% BY27-010                                                                          Al.sub.2 O.sub.3 -80 grit                                                             silane                                                                             30%                                           21 94% YC-1004                                                                           10% BY27-010                                                                          Al.sub.2 O.sub.3 -80 grit                                                             silane                                                                             30%                                           22 100% KS075P                                                                           --      Al.sub.2 O.sub.3 -80 grit                                                             silane                                                                             35%                                           23 100% KS084P                                                                           --      Al.sub.2 O.sub.3 -80 grit                                                             silane                                                                             35%                                           24 100% KS084P                                                                           --      Al.sub.2 O.sub.3 -80 grit                                                             silane                                                                             35%                                           25 51% Hytrel 5526                                                                       25.5% YL-4030                                                                         Al.sub.2 O.sub.3 -80 grit                                                             silane                                                                             30%                                              23.5% YC-1004                                                                         (3.8% PTFE)                                                        26 78% Hytrel 5526                                                                       12% BY27-010                                                                          Al.sub.2 O.sub.3 -80 grit                                                             silane                                                                             30%                                              10% YC-1004                                                                27 90% Hytrel 5526                                                                       10% BY27-010                                                                          Al.sub.2 O.sub.3 -80 grit                                                             Z-6030                                                                             30%                                           28 90% Hytrel 5526                                                                       10% BY27-010                                                                          Al.sub.2 O.sub.3 -80 grit                                                             Z-6075                                                                             30%                                           29 90% Hytrel 5526                                                                       10% BY27-010                                                                          Al.sub.2 O.sub.3 -60 grit                                                             silane                                                                             30%                                           30.sup.1                                                                         90% Hytrel 5526                                                                       10% BY27-010                                                                          Al.sub.2 O.sub.3 -60 grit                                                             silane                                                                             30%                                           31 90% Hytrel 5556                                                                       10% BY27-010                                                                          Al.sub.2 O.sub.3 -60 grit                                                             silane                                                                             30%                                           32.sup.1                                                                         90% Hytrel 5556                                                                       10% BY27-010                                                                          Al.sub.2 O.sub.3 -60 grit                                                             silane                                                                             30%                                           33 90% Pebax                                                                             10% BY27-010                                                                          Al.sub.2 O.sub.3 -60 grit                                                             silane                                                                             30%                                           34 90% Duraflex                                                                          10% BY27-010                                                                          Al.sub.2 O.sub.3 -60 grit                                                             silane                                                                             30%                                           35 90% B0100                                                                             10% BY27-010                                                                          Al.sub.2 O.sub.3 -60 grit                                                             silane                                                                             30%                                           36 90% Estane                                                                            10% BY27-010                                                                          Al.sub.2 O.sub.3 -60 grit                                                             silane                                                                             30%                                              58092                                                                      37 90% Estane                                                                            10% BY27-010                                                                          Al.sub.2 O.sub.3 -60 grit                                                             silane                                                                             30%                                              58091                                                                      38 90% Hytrel 5526                                                                       10% BY27-010                                                                          Al.sub.2 O.sub.3 -50 grit                                                             silane                                                                             30%                                           39 90% Hytrel 5526                                                                       10% BY27-010                                                                          SiC-60 grit                                                                           --   30%                                           40 90% Hytrel 5526                                                                       10% BY27-010                                                                          CA02-60 grit                                                                          --   30%                                           41 90% Hytrel 5526                                                                       10% BY27-010                                                                          MC3-30/40 mesh                                                                        --   30%                                           __________________________________________________________________________     .sup.1 molded polymer included orange pigment                                 .sup.2 molded polymer included yellow pigment                            

Performance Testing Individual abrasive brushes 10 were tested on anapparatus that applied a load of 1.8 kg (4 lb.) for 20 seconds, thenlifted for 11 seconds. This was repeated for 30 cycles for a total testtime of 10 minutes on the workpiece. The workpiece was a flat plate of5052 aluminum, 38.1×38.1 cm×0.32 cm (15×15×1/8 inch) with a 0.64 cm (1/4inch) central hole to mount it on the test apparatus. The plate wasrotated at about 1 revolution every 3 minutes. The abrasive brushes weremounted on an Ingersoll-Rand cyclone series right angle grinder, modelTA 180 RG4 rated at 18,000 rpm and 0.70 hp. The abrasive brush was runat 18,000 RPM free spinning (actual RPM under load was somewhat less).The abrasive brush was held at a 7° angle to the workpiece. The weightloss of the plate is recorded as cut. The weight loss and lengthreduction of the bristles of the abrasive brush are recorded as wear.Finish, Ra, was recorded after performance testing, and may not be asgood as optimally attainable for each particular example, because theperformance testing results in multiple passes being made over the samearea of the workpiece. The results reported are the average of twobrushes of the same composition, unless otherwise noted. Somecompositions were tested both with fillet A and fillet B, some were nottested using this method.

                  TABLE 2                                                         ______________________________________                                        (fillet A)                                                                                                    Broken Ra Finish                              Example                                                                              Cut, g  Wear, g Wear, mm (in)                                                                          Bristles                                                                             (micro inch)                           ______________________________________                                        2      2.9     0.6     1.83 (0.072)                                                                           0      29                                     4      3.5     0.7     0.99 (0.039)                                                                           7      36                                     6      12.8    0.9     1.52 (0.060)                                                                           9      42                                     8      10.4    1.8     1.78 (0.070)                                                                           27     41                                     10     4.4     0.7     0.89 (0.035)                                                                           8      27                                     15     13.9    1.1     1.47 (0.058)                                                                           14     46                                     ______________________________________                                    

                  TABLE 3                                                         ______________________________________                                        (fillet B)                                                                                                    Broken Ra Finish                              Example                                                                              Cut, g  Wear, g Wear, mm (in)                                                                          Bristles                                                                             (micro inch)                           ______________________________________                                        6      13.8    0.9     1.37 (0.054)                                                                           8      40                                     15     15.3    1.1     1.85 (0.073)                                                                           8      51                                     18     9.8     0.8     1.27 (0.050)                                                                           0      34                                     19     12.0    0.9     1.63 (0.064)                                                                           0      36                                     20     12.2    0.9     1.75 (0.069)                                                                           0      33                                     20     12.5    0.9     1.63 (0.064)                                                                           0      40                                     23.sup.1                                                                      25     6.0     0.5     0.89 (0.035)                                                                           5      35                                     26     12.1    0.9     1.63 (0.064)                                                                           1      36                                     27     10.9    0.9     1.60 (0.063)                                                                           0      39                                     28     10.9    0.8     1.55 (0.061)                                                                           0      34                                     29     16.4    1.2     2.01 (0.079)                                                                           3      46                                     30     17.1    1.7     2.11 (0.083)                                                                           1      42                                     31     15.2    1.1     1.75 (0.069)                                                                           0      42                                     32     15.1    1.1     1.80 (0.071)                                                                           0      42                                     33     3.0     0.1     0.13 (0.005)                                                                           0      45                                     34.sup.2                                                                      35.sup.3                                                                      36.sup.4                                                                      37.sup.5                                                                      38     21.4    1.5     2.54 (0.100)                                                                           1      50                                     39     13.0    1.2     2.01 (0.079)                                                                           2      37                                     40     20.3    1.8     2.87 (0.113)                                                                           9      49                                     41.sup.6                                                                             0       0       0.00 (0.000)                                                                           0      N.A.                                   ______________________________________                                         .sup.1 bristles melted, only one brush tested                                 .sup.2 failed at 1 & 10 cycles  melted bristles                               .sup.3 attaching means failed at 10 & 18 cycles                               .sup.4 attaching means failed at 3 & 4 cycles                                 .sup.5 failed at 10 & 30 cycles  melted bristles                              .sup.6 plastic abrasive particles                                        

EXAMPLES 42-70

Performance Testing

Performance testing was the same as for examples 1-41, except for thefollowing. All examples had a fillet radius of approximately 0.025inches. Results for the aluminum test pieces are the average of twotests, results for cold rolled steel (CRS) are a single test, resultsfor stainless steel (SS) are a single test. Microfinish (reported as Raand Rz in micro-inches) is the result after hand testing a particularbrush example on a different test piece than that used for theperformance testing, with the finish prior to refining the surface being(in micro-inches):

    ______________________________________                                        aluminum         Ra: 7       Rz: 40                                           CRS              Ra: 31      Rz: 151                                          Stainless Steel  Ra: 11      Rz: 72                                           ______________________________________                                    

Composition of the example abrasive brushes is reported in Table 4, testresults on aluminum in Table 5, tests results on cold rolled steel inTable 6 (not all examples tested); test results on stainless steel inTable 7 (not all examples tested). No broken bristles were observed inExamples 42-70.

                                      TABLE 4                                     __________________________________________________________________________                       Abrasive Particles                                         Moldable Polymer           Coupling                                                                           Abrasive                                      Ex.                                                                              TP and/or TPE                                                                         Lubricant                                                                             Particle                                                                              Agent                                                                              Content                                       __________________________________________________________________________    42 90% Hytrel 5526                                                                       10% BY27-010                                                                          Al.sub.2 O.sub.3 -80 grit                                                             silane                                                                             30%                                           43 90% Hytrel 5526                                                                       10% BY27-010                                                                          Al.sub.2 O.sub.3 -50 grit                                                             silane                                                                             30%                                           44 80% Hytrel 5526                                                                       20% BY27-010                                                                          Al.sub.2 O.sub.3 -600 grit                                                            --   30%                                           45 80% Hytrel 5526                                                                       20% BY27-010                                                                          Al.sub.2 O.sub.3 -400 grit                                                            --   30%                                           46 80% Hytrel 5526                                                                       20% BY27-010                                                                          Al.sub.2 O.sub.3 -320 grit                                                            --   30%                                           47 80% Hytrel 5526                                                                       20% BY27-010                                                                          Al.sub.2 O.sub.3 -220 grit                                                            --   30%                                           48 80% Hytrel 5526                                                                       20% BY27-010                                                                          Al.sub.2 O.sub.3 -220 grit                                                            silane                                                                             30%                                           49 80% Hytrel 5526                                                                       20% BY27-010                                                                          SiC-220 grit                                                                          --   26%                                           50 80% Hytrel 5526                                                                       20% BY27-010                                                                          Al.sub.2 O.sub.3 -180 grit                                                            --   30%                                           51 80% Hytrel 5526                                                                       20% BY27-010                                                                          Al.sub.2 O.sub.3 - 150 grit                                                           silane                                                                             30%                                           52 80% Hytrel 5526                                                                       20% BY27-010                                                                          Al.sub.2 O.sub.3 -120 grit                                                            silane                                                                             30%                                           53 80% Hytrel 5526                                                                       20% BY27-010                                                                          Al.sub.2 O.sub.3 -120 grit                                                            --   30%                                           54 80% Hytrel 5526                                                                       20% BY27-010                                                                          SiC-120 grit                                                                          --   26%                                           55 80% Hytrel 5526                                                                       20% BY27-010                                                                          Al.sub.2 O.sub.3 -100 grit                                                            silane                                                                             30%                                           56 80% Hytrel 5526                                                                       20% BY26-010                                                                          Al.sub.2 O.sub.3 (h) 80 grit                                                          --   30%                                           57 80% Hytrel 5526                                                                       20% BY27-010                                                                          Al.sub.2 O.sub.3 -80 grit                                                             --   30%                                           58 80% Hytrel 5526                                                                       20% BY27-010                                                                          Al.sub.2 O.sub.3 -80 grit                                                             silane                                                                             30%                                           59 80% Hytrel 5526                                                                       20% BY27-010                                                                          CA02-80 grit                                                                          --   30%                                           60 80% Hytrel 5526                                                                       20% BY27-010                                                                          CA03-P120 grit                                                                        --   30%                                           61 80% Hytrel 5526                                                                       20% BY27-010                                                                          CA03-P220 grit                                                                        --   30%                                           62 80% Hytrel 5526                                                                       20% BY27-010                                                                          Al.sub.2 O.sub.3 -60 grit                                                             silane                                                                             30%                                           63 80% Hytrel 5526                                                                       20% BY27-010                                                                          Al.sub.2 O.sub.3 -50 grit                                                             silane                                                                             30%                                           64 80% Hytrel 5526                                                                       20% BY27-010                                                                          Al.sub.2 O.sub.3 -50 grit                                                             --   30%                                           65 80% Hytrel 5526                                                                       20% BY27-010                                                                          SiC-50 grit                                                                           --   26%                                           66 80% Hytrel 5526                                                                       20% BY27-010                                                                          CA02-50 grit                                                                          silane                                                                             30%                                           67 80% Hytrel 5556                                                                       20% BY27-010                                                                          Al.sub.2 O.sub.3 -120 grit                                                            silane                                                                             30%                                           68 80% Hytrel 5556                                                                       20% BY27-010                                                                          Al.sub.2 O.sub.3 -50 grit                                                             silane                                                                             30%                                           69 100% Pebax 5533                                                                       --      Al.sub.2 O.sub.3 -50 grit                                                             silane                                                                             30%                                           70 90% Pebax 5533                                                                        10% BY27-010                                                                          Al.sub.2 O.sub.3 -60 grit                                                             silane                                                                             40%                                           __________________________________________________________________________

                  TABLE 5                                                         ______________________________________                                        (results on aluminum)                                                         Example                                                                              Cut, g   Wear, g  Wear, mm (in)                                                                           Ra    Rz                                   ______________________________________                                        42     11.8     0.7      1.52 (0.060)                                                                            39.0  254                                  43     16.7     1.2      2.13 (0.084)                                                                            56.5  336                                  44     0.2      0.1      0.33 (0.013)                                                                            6.7   45                                   45     0.2      0.2      0.33 (0.013)                                                                            9.1   59                                   46     0.4      0.1      0.28 (0.011)                                                                            7.1   48                                   47     2.0      0.2      0.64 (0.025)                                                                            8.8   58                                   48     2.0      0.2      0.61 (0.024)                                                                            11.5  73                                   49     2.1      0.3      0.71 (0.028)                                                                            10.6  69                                   50     2.2      0.2      0.61 (0.024)                                                                            12.9  82                                   51     2.6      0.4      0.66 (0.026)                                                                            16.5  103                                  52     4.2      0.4      0.86 (0.034)                                                                            19.2  116                                  53     3.9      0.3      0.76 (0.030)                                                                            17.3  108                                  54     2.7      0.3      0.86 (0.034)                                                                            17.5  114                                  55     6.7      0.4      0.97 (0.038)                                                                            23.5  141                                  56     12.2     0.7      1.37 (0.054)                                                                            33.0  197                                  57     10.3     0.7      1.12 (0.044)                                                                            26.9  157                                  58     11.3     0.7      1.35 (0.053)                                                                            31.0  178                                  59     12.5     0.8      1.45 (0.057)                                                                            40.5  224                                  60     5.9      0.4      0.94 (0.037)                                                                            23.0  138                                  61     2.1      0.2      0.76 (0.030)                                                                            11.6  74                                   62     13.7     0.8      1.62 (0.060)                                                                            40.0  227                                  63     17.4     1.0      1.70 (0.067)                                                                            39.5  223                                  64     16.5     0.9      1.75 (0.069)                                                                            52.0  298                                  65     10.0     0.9      1.65 (0.065)                                                                            34.5  192                                  66     19.6     1.1      2.03 (0,080)                                                                            46.0  286                                  67     4.0      0.3      0.84 (0.033                                                                             18.1  120                                  68     17.6     1.0      1.85 (0.073)                                                                            55.0  344                                  69     2.8      5.2      8.99 (0.354)                                                                            54.0  320                                  70     2.8      0.1      0.18 (0.007)                                                                            39.5  242                                  ______________________________________                                    

                  TABLE 6                                                         ______________________________________                                        (results on cold rolled steel)                                                Example                                                                              Cut, g   Wear, g  Wear, mm (in)                                                                           Ra    Rz                                   ______________________________________                                        47     0.3      0.1      0.025 (0.001)                                                                           22    112                                  48     0.4      0.0      0.076 (0.003)                                                                           23    113                                  49     0.5      0.0      0.10 (0.004)                                                                            20    109                                  52     0.8      0.1      0.051 (0.002)                                                                           16    84                                   53     0.6      0.1      0.076 (0.003)                                                                           21    116                                  54     0.9      0.1      0.15 (0.006)                                                                            18    97                                   56     1.6      0.0      0.13 (0.005)                                                                            25    152                                  57     1.1      0.0      0.13 (0.005)                                                                            24    150                                  58     1.3      0.0      0.076 (0.003)                                                                           23    142                                  59     1.9      0.0      0.051 (0.002)                                                                           20    119                                  60     1.0      0.0      0.10 (0.004)                                                                            18    106                                  61     0.5      0.1      0.076 (0.003)                                                                           17    87                                   63     4.2      0.0      0.13 (0.005)                                                                            22    131                                  64     3.2      0.1      0.18 (0.007)                                                                            29    176                                  65     2.5      0.1      0.23 (0.009)                                                                            15    95                                   66     4.7      0.1      0.15 (0.006)                                                                            30    177                                  ______________________________________                                    

                  TABLE 7                                                         ______________________________________                                        (results on stainless steel)                                                  Ex-   Bristle                        Ra    Rz                                 ample Melt.sup.1                                                                            Cut, g  Wear, g                                                                             Wear, mm (in)                                                                          (μ in)                                                                           (μ in)                          ______________________________________                                        47    3       0.5     1.0   0.025 (0.112)                                                                          5.4   39                                 48    1       0.4     0.0   0.076 (0.002)                                                                          6.3   48                                 49    2       0.3     0.0   0.10 (0.019)                                                                           4.8   40                                 52    2       0.8     0.1   0.051 (0.031)                                                                          9.7   74                                 53    1       0.6     0.0   0.076 (0.010)                                                                          8.5   60                                 54    2       0.8     0.1   0.15 (0.024)                                                                           6.3   46                                 56    1       2.0     0.1   0.13 (0.003)                                                                           14.5  103                                57    3       2.2     0.5   0.13 (0.073)                                                                           15.5  112                                58    2       2.1     0.1   0.076 (0.016)                                                                          10.7  80                                 59    1       2.2     0.0   0.051 (0.005)                                                                          17.0  119                                60    3       1.4     0.4   0.10 (0.065)                                                                           10.9  78                                 61    3       0.4     0.5   0.076 (0.056)                                                                          6.9   50                                 63.sup.2                                                                            3       0.5     1.6   0.13 (0.155)                                                                           12.1  83                                 64.sup.3                                                                            3       1.1     1.6   0.18 (0.151)                                                                           18.6  126                                65    1       1.5     0.1   0.23 (0.007)                                                                           18.9  138                                66.sup.2                                                                            3       0.4     1.4   0.15 (0.142)                                                                           20.6  142                                ______________________________________                                         .sup.1 Bristle melt: 1 = none or negligible; 2 = minor; 3 = unacceptable      (brush inoperative)                                                           .sup.2 Test stopped at 2 cycles                                               .sup.3 Test stopped at 6 cycles                                          

EXAMPLE 71

A molded abrasive brush 110 to be utilized on a rotary floor machine wasprepared generally according to the embodiment of FIGS. 11-12 byinjection molding a Hytrel™ 5526 polyester based thermoplastic elastomer(available from Du Pont) that was compounded to contain 30% by weight120 grade silicon carbide abrasive. The material was pelletized aftercompounding. The pelletized compound was injection molded on a 75 tonVan Dorn press utilizing a mud set plastic injection prototype mold asdescribed above with respect to examples 1-70. Mold temperature was 60°C. (140° F.) and melt temperature was approximately 237° C. (460° F.).Cycle time was 30 seconds. Part weight was 32.5 grams.

The base 112 was a generally wedge-shaped polygon, 10.5 cm (4.125 in)long by 3.8 cm (1.50 in) wide at one end and 2.2 cm (0.875 in) wide atthe opposite end. Extending from one major surface were 440 bristles 118each 1.9 cm (0.75 in) long, 2.3 mm (0.090 in) diameter at the root and1.0 mm (0.040 in) diameter at tip 122. The 9.5 mm (0.375 in) longportion of the bristle 118 adjacent tip 122 was cylindrical.

The present invention has now been described with reference to severalembodiments thereof. The foregoing detailed description and exampleshave been given for clarity of understanding only. No unnecessarylimitations are to be understood therefrom. It will be apparent to thoseskilled in the art that many changes can be made in the embodimentsdescribed without departing from the scope of the invention. Forexample, the abrasive brush according to the present invention may beprovided with means for introducing fluid such as coolants, lubricants,and cleaning fluids to the workpiece during operation as is known in theart, such as by openings through the backing or bristles. Thus, thescope of the present invention should not be limited to the exactdetails and structures described herein, but rather by the structuresdescribed by the language of the claims, and the equivalents of thosestructures.

What is claimed is:
 1. An integrally molded abrasive brush comprising:aflexible base having a first side and a second side, wherein said baseis generally planar, wherein said base is capable of flexing at least20° without damage or substantial permanent deformation to said base;and a plurality of bristles extending from said first side of said base,wherein said bristles have an aspect ratio of at least 2, and whereinsaid bristles are integrally molded with said base; wherein said moldedabrasive brush comprises a moldable polymeric material and wherein saidmoldable polymeric material includes abrasive particles interspersedthroughout at least said plurality of bristles.
 2. The molded abrasivebrush of claim 1, wherein said bristles have an aspect ratio of at least5.
 3. The molded abrasive brush of claim 1, wherein said bristles havean aspect ratio of at least
 7. 4. The molded abrasive brush of claim 1,wherein said bristles each comprise a root adjacent said base and a tipopposite said base, and wherein said bristles are tapered so as to bewider at said root than at said tip.
 5. The molded abrasive brush ofclaim 4, wherein said bristles are tapered at a first portion adjacentsaid root, and wherein said bristles have a constant thickness at asecond portion adjacent said tip.
 6. The molded abrasive brush of claim4, wherein said bristles include a fillet radius at the transition fromsaid root to said base.
 7. The molded abrasive brush of claim 1, furthercomprising an attachment means provided on said base for attaching saidabrasive brush to a tool.
 8. The molded abrasive brush of claim 7,wherein said attachment means comprises a threaded stud integrallymolded with said base and extending from said second side of said base.9. The molded abrasive brush of claim 1, wherein said moldable polymericmaterial comprises a thermoplastic elastomer.
 10. The molded abrasivebrush of claim 9, wherein said thermoplastic elastomer comprises apolyester based thermoplastic elastomer.
 11. The molded abrasive brushof claim 1, wherein said moldable polymer further comprises a lubricant.12. The molded abrasive brush of claim 9, wherein said thermoplasticelastomer comprises a plurality of abrasive particles interspersedthroughout said abrasive brush.
 13. The molded abrasive brush of claim1, wherein said abrasive particles comprise inorganic abrasiveparticles.
 14. The molded abrasive brush of claim 1, wherein saidabrasive particles comprise organic abrasive particles.
 15. The moldedabrasive brush of claim 1, wherein said base includes a reinforcingmeans for reinforcing said base.
 16. The molded abrasive brush of claim15, wherein said reinforcing means comprises a reinforcing substrateprovided on said second side of said base.
 17. The molded abrasive brushof claim 1, wherein said base is circular.
 18. The molded abrasive brushof claim 1, wherein said base is polygonal.
 19. The molded abrasivebrush of claim 18 in combination with a backing having a first majorsurface, wherein said molded abrasive brush is mounted on said firstmajor surface of said backing to thereby form a brush assembly.
 20. Thebrush assembly of claim 19, wherein said backing is circular and saidassembly comprises a plurality of said abrasive brushes mounted on saidfirst major surface in an substantially equal angular spacing.
 21. Anintegrally molded abrasive brush comprising:a base having a first sideand a second side, wherein said base is capable of flexing at least 20°without damage or substantial permanent deformation to said base; and aplurality of bristles extending from said first side of said base,wherein said bristles are integrally molded with said base; wherein saidmolded abrasive brush comprises a thermoplastic elastomer includingabrasive particles interspersed throughout at least said plurality ofbristles.
 22. The molded abrasive brush of claim 21, wherein said baseis generally planar.
 23. The molded abrasive brush of claim 21, whereinsaid thermoplastic elastomer is selected from the group consistingessentially of: polyester-based thermoplastic elastomer, nylon-basedthermoplastic elastomer, and polyurethane-based thermoplastic elastomer.24. The molded abrasive brush of claim 21, wherein said thermoplasticelastomer comprises a polyester-based thermoplastic elastomer.
 25. Themolded abrasive brush of claim 21, wherein said base is circular. 26.The molded abrasive brush of claim 21, wherein said base is polygonal.27. The molded abrasive brush of claim 26 in combination with a backinghaving a first major surface, wherein said molded abrasive brush ismounted on said first major surface of said backing to thereby form abrush assembly.
 28. The brush assembly of claim 27, wherein said backingis circular and said assembly comprises a plurality of said abrasivebrushes mounted on said first major surface in an substantially equalangular spacing.
 29. An integrally molded abrasive brush comprising:abase having a first side and a second side, wherein said base is capableof flexing at least 20° without damage or substantial permanentdeformation to said base; a plurality of bristles extending from saidfirst side of said base, wherein said bristles are integrally moldedwith said base; and a threaded stud integrally molded with said base andextending from said second side of said base for attaching said abrasivebrush to a tool to rotate said abrasive brush; wherein said moldedabrasive brush comprises a moldable polymeric material and wherein saidmoldable polymeric material includes abrasive particles interspersedthroughout at least said plurality of bristles.
 30. An integrally moldedabrasive brush comprising:a base having a first side and a second side,wherein said base is capable of flexing at least 20° without damage orsubstantial permanent deformation to said base; and a plurality ofbristles extending from said first side of said base, wherein saidbristles are integrally molded with said base; wherein said moldedabrasive brush comprises a thermoplastic elastomer and wherein saidthermoplastic elastomer includes organic abrasive particles interspersedthroughout at least said plurality of bristles.
 31. The molded abrasivebrush of claim 30, wherein said thermoplastic elastomer comprises aplurality of organic abrasive particles interspersed throughout saidabrasive brush.
 32. An integrally molded abrasive brush comprising:agenerally circular base having a first side and a second side, whereinsaid base is capable of flexing at least 20° without damage orsubstantial permanent deformation to said base; and a plurality ofbristles extending from said first side of said base, wherein saidbristles have an aspect ratio of at least 2, and wherein said bristlesare integrally molded with said base; wherein said molded abrasive brushcomprises a moldable polymeric material and wherein said moldablepolymeric material includes abrasive particles interspersed throughoutat least said plurality of bristles.
 33. The integrally molded abrasivebrush of claim 32, further comprising an attachment means integrallymolded with said base and located at the center of said circular base.34. An integrally molded abrasive brush comprising:a base having a firstside and a second side, wherein said base is capable of flexing at least20° without damage or substantial permanent deformation to said base;and a plurality of bristles extending from said first side of said base,wherein said bristles are integrally molded with said base; wherein saidmolded abrasive brush comprises a thermoplastic elastomer includingabrasive particles interspersed throughout at least said plurality ofbristles.
 35. The integrally molded abrasive brush of claim 34, whereinsaid base in generally circular, and further comprising an attachmentmeans integrally molded with said base and located at the center of saidcircular base.
 36. An integrally molded abrasive brush comprising:agenerally circular base having a first side and a second side, whereinsaid base is capable of flexing at least 20° without damage orsubstantial permanent deformation to said base; a plurality of bristlesextending from said first side of said base, wherein said bristles areintegrally molded with said base; and a threaded stud integrally moldedwith said base and extending from the center of said second side of saidbase for attaching said abrasive brush to a tool to rotate said abrasivebrush; wherein said molded abrasive brush comprises a moldable polymericmaterial and wherein said moldable polymeric material includes abrasiveparticles interspersed throughout at least said plurality of bristles.